FEATURE Smart Factories
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Key factors for a successful smart factory journey
Nguyen Duc Kinh, Senior Vice President and Executive Director of the Global Automotive & Manufacturing Solutions Group at FPT Software, explains five areas manufacturers should focus on to turn their ambition into reality
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mart manufacturing has become the topic of interest globally, thanks to the huge and diversifi ed benefi ts it off ers. Asset effi ciency,
lower cost, higher product quality, improved safety and sustainability are all among the expected positive impacts from next-generation, connected factories. Industrial manufacturing is experiencing one of the most exciting phases in its history thanks to the latest technology advancements. Smart manufacturing opens up endless opportunities for companies to maximise their effi ciency, conquer new markets and drive innovation. Yet, many companies have not reaped adequate outcomes from their IoT investments. Although there is no formula for success, careful consideration and preparation will allow manufacturers to clearly map out and accelerate their transformation journey. So, what are the key factors that could enable a successful implementation?
Well-prepared data strategy Whereas steam and electricity revolutionised the manufacturing industry in the past, today it is data that is disrupting how manufacturers operate. In a factory, valuable data can be collected from embedded sensors and connected production equipment, such as conveyors, fastening tools or robots – data that can come in many forms, for example, text, images, video, or sound recordings. To fully exploit the power of data, companies need the right infrastructure, consisting of connected devices, networks, protocols and storage, to support their ever-growing data flow. In addition, since most legacy systems in factories were designed independently and often lack the ability to communicate with each other, manufacturers need to unify data from disparate sources to create a single source of information.
16 April 2023 | Automation
may no longer be necessary thanks to the adoption of robots, while other workers may be required to develop new capabilities to fully utilise advanced technologies. It is also likely that new roles will emerge. An under-skilled workforce is not something today’s manufacturers can aff ord. To ensure the successful collaboration between humans and machines, both managing and operational levels are required to be quick learners, more versatile, fl exible and proactive, so they can perform cross- functional roles. Not only do they need deep domain knowledge, technical know- how about handling equipment, data and automation are also essential.
Process optimisation A key benefi t to gain from smart manufacturing is to augment processes for better operational effi ciency. Yet, to accelerate and maximise the positive impact of any digital initiatives, manufacturers are advised to adjust or even redesign their processes in preparation for their Industry 4.0 factory.
Since the implementation of smart manufacturing not only aff ects production lines but also other shop fl oor activities and top fl oor operations like sales, fi nance and even HR, badly organised procedures might impede the adoption of new technologies, especially when it comes to automation. This could have a negative impact on the manufacturer’s entire performance. Digital connectivity also allows increased links with suppliers, customers and other production sites, forcing manufacturers to streamline their processes to avoid any accidents that may result from poor operation models.
Workforce with modern skillsets No matter how smart factories can become, people are still the key to success. However, manufacturing digitalisation can lead to profound changes in an organisation’s human resources structure. Some positions
Readiness for rapid changes Manufacturing technologies advance every day. A few years ago, drones, autonomous vehicles, robotics and 3D printing were still novelties, but today they are readily adopted across many sectors. To remain competitive, organisations must be up to date with and open to emerging technologies such as data analytics, high-performance computing, artifi cial intelligence, blockchain, intuitive machinery and augmented reality.
More attention on cybersecurity Smart manufacturing relies heavily on tools and systems connectivity, making them vulnerable to unauthorised access, data leaks, espionage and even sabotage. Given the multitude of connection points, a cyber attack may cause a more signifi cant and widespread impact. At the same time, it is more diffi cult to protect complex systems against growing cyber threats. Overcoming these challenges requires stricter measures, including proper investments in robust IT infrastructure and security skills.
CONTACT:
FPT Software
www.fpt-software.com
automationmagazine.co.uk
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